The Challenge
Orion Logistics, a regional e-commerce fulfillment provider, was expanding operations into a 200,000 sq ft facility in Grand Rapids. As part of their growth, they integrated high-speed sortation systems, automated packaging lines, and 24/7 staffing across multiple shifts.
Within weeks of full operation, employees reported communication issues and elevated stress in several high-noise zones. A preliminary internal survey also flagged potential OSHA exposure risks in the packing and loading dock areas.
Orion needed fast, compliant, and minimally disruptive noise control to protect staff and avoid potential citations.
Our Approach
Memtech Acoustical was engaged to assess, design, and implement a site-wide noise control program.
Our team
- Performed a complete noise exposure survey using personal dosimeters and real-time area sound mapping during peak operations.
- Identified key noise sources including automated rollers, overhead conveyors, and truck loading bays.
- Used octave band and frequency analysis to understand the dominant sound profiles and target controls accordingly.
- Delivered a predictive acoustic model to simulate control outcomes before product selection or installation.
- Collaborated with Orion’s safety and operations leads to align recommendations with workflow and access needs.
The Solution
We implemented a multi-faceted, scalable solution:
- Installed barrier-backed acoustical curtain enclosures around the sortation system, reducing direct-path noise without affecting access.
- Added wall-mounted acoustic panels in reverberant zones like the packaging area to reduce overall echo and ambient volume.
- Designed and deployed sound barrier walls along the loading dock perimeter to contain truck and machinery noise.
- Delivered OSHA-compliant Hearing Conservation Program materials including training, signage, and recordkeeping templates.
All systems were installed during off-shifts and weekends to avoid interfering with order fulfillment operations.
The Results
- Achieved a 13 dBA reduction in the packing and sorting zones, bringing average exposure below 82 dBA.
- Enabled clear verbal communication across 20+ workstations previously impacted by background noise.
- Passed an unscheduled OSHA site inspection with no citations.
- Improved employee satisfaction scores in follow-up EHS feedback by 40%.
- Provided a scalable solution that Orion now plans to replicate in two additional facilities.
Acoustical Services Delivered
- Noise exposure testing and personal dosimetry
- Predictive noise modeling and source prioritization
- Curtain wall system design and installation
- Acoustic panel engineering and mounting support
- OSHA compliance training and documentation packages
- Ongoing monitoring support for future expansions
